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Fricke Wolfgang. - Structural Hot-Spot Stress Approach to Fatigue Analysis of Welded Components: Designers Guide

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Fricke Wolfgang. Structural Hot-Spot Stress Approach to Fatigue Analysis of Welded Components: Designers Guide
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Structural Hot-Spot Stress Approach to Fatigue Analysis of Welded Components: Designers Guide: summary, description and annotation

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Introduction -- The Structural Hot-Spot Approach To Fatigue Analysis -- Experimental Determination Of The Structural Hot- Spot Stress -- Structural Hot-Spot Stress Determination Using Finite Element Analysis -- Parametric Formulae -- Structural Hot-Spot S-N Curves -- Case Study 1 -- Case Study 2 -- Case Study 3 -- Case Study 4.;This book provides background and guidance on the use of the structural hot-spot stress approach to fatigue analysis. It also offers Design S-N curves for use with the structural hot-spot stress for a range of weld details, and presents parametric formulas for calculating stress increases due to misalignment and structural discontinuities. Highlighting the extension to structures fabricated from plates and non-tubular sections. The structural hot-spot stress approach focuses on cases of potential fatigue cracking from the weld toe and it has been in use for many years in tubular joints. Following an explanation of the structural hot-spot stress, its definition and its relevance to fatigue, the book describes methods for its determination. It considers stress determination from both finite element analysis and strain gauge measurements, and emphasizes the use of finite element stress analysis, providing guidance on the choice of element type and size for use with either solid or shell elements. Lastly, it illustrates the use of the recommendations in four case studies involving the fatigue assessment of welded structures using the structural hot-spot stress.

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Springer Nature Singapore Pte Ltd. 2018
Erkki Niemi , Wolfgang Fricke and Stephen J. Maddox Structural Hot-Spot Stress Approach to Fatigue Analysis of Welded Components IIW Collection
1. Introduction
Erkki Niemi 1
(1)
Department of Mechanical Engineering, Lappeenranta University of Technology, Lappeenranta, Finland
(2)
Institute of Ship Structural Design and Analysis, Hamburg University of Technology, Hamburg, Germany
(3)
The Welding Institute, Cambridge, UK
Erkki Niemi (Corresponding author)
Email:
Wolfgang Fricke
Email:
Stephen J. Maddox
Email:
1.1 General
Traditional fatigue analysis of welded components is based on the use of nominal stresses and catalogues of classified details. A particular type of detail is assigned to a particular fatigue class with a given S - N curve. Such a method is used in the IIW fatigue design recommendations []. This nominal stress approach ignores the actual dimensional variations of a particular structural detail, which is an obvious drawback. Moreover, the form of a welded component is often so complex that the determination of the nominal stress is difficult or impossible. This is true even if the finite element analysis (FEA) method is used for the stress analysis.
In the context of potential fatigue failure by crack growth from the weld toe or end, the structural hot-spot stress approach goes one step forward. Here the calculated stress does take into consideration the dimensions of the detail. The resulting structural stress at the anticipated crack initiation site (hot-spot) is called the structural hot-spot stress. Structural stress includes the stress concentrating effects of the detail itself but not the local non-linear stress peak caused by the notch at the weld toe. This notch effect is included in the hot spot S - N curve determined experimentally. This is reasonable because the exact geometry of the weld will not be known at the design stage. The variation in the local geometry of the weld toe is one of the main reasons for scatter in fatigue test results. By using the lower-bound characteristic S - N curve, lower bound quality of the weld toe is incorporated into the analysis. A single S - N curve should suffice for most forms of structural discontinuity, providing the weld toe geometry is always the same.
An obvious reason for introducing the structural hot-spot approach is the availability of powerful computers and software, which make detailed FEA possible for most design offices. However, the approach is also a valuable tool for choosing the locations of strain gauges when validating design by field-testing prototype structures. Moreover, finite element analyses make it possible to produce parametric formulae in advance for easy estimation of structural stresses at various hot-spots.
The hot-spot approach was first developed for fatigue analysis of welded tubular joints in offshore structures. Corresponding fatigue design rules were published by the American Petroleum Institute, the American Welding Society, Bureau Veritas, UK Department of Energy, etc. A review of this topic can be found in Ref. []. There is now an increasing demand for application of the approach to be extended to all kinds of plated structures. Some progress has been made in doing this, but at present there are differences in the methods recommended for estimating the structural hot-spot stress.
The first general design rule to include the structural stress (referred to at the time as the geometric stress) approach was the European pre-standard ENV 1993-1-1 [].
Subsequently, further research has led to improved procedures for determining the structural hot-spot stress, particularly using FEA []. Furthermore, the ability to establish through-thickness stress distributions using FEA has enabled a method to be developed that uses this information to calculate the structural hot-spot stress. Previously attention has focussed on use of the surface stress distribution, approaching the weld in question, and determination of the structural hot-spot stress using an extrapolation procedure. Use of the through-thickness stress distribution instead should avoid the need for extrapolation.
The goal of the present document is to help design engineers and stress analysts to implement the structural hot-spot approach in practice. Practical examples of the application of the methods described are given in the form of Case Studies in Chaps. ].
In view of the scope of current experience and the availability of relevant fatigue test data, the recommendations presented in this document are only intended for plate thicknesses above 3 mm. However, the structural hot-spot stress has successfully been applied also to thinner plated structures, e.g. in the automotive industry.
1.2 Safety Aspects
When using this document, the general guidelines on fatigue analysis and safety aspects given in the latest version of the IIW Recommendations [] should be taken into consideration. For example, it may be appropriate to multiply the fatigue loads by a partial safety factor, F, which will normally be specified in the appropriate design code for a particular structure. Similarly, the fatigue strength may need to be divided by M, as required.
It should be noted that the S - N curves presented in this document do not include any allowance for inaccuracies in stress determination. Furthermore, the stress raising effect of misalignment in welded joints and other such imperfections may not have been taken into account. If the stress analyst chooses to simplify the stress determination, for example by omitting the extrapolation of the structural stress to the weld toe or by totally neglecting misalignment, the load factor, F, should be increased accordingly.
References
Hobbacher, A.F.: Recommendations for fatigue design of welded joints and components, 2nd edn. Springer (2016)
Marshall, P.W.: Design of welded tubular connections. Basis and use of AWS code provisions. Dev. Civ Eng. ,412. Elsevier (1992)
ENV 1993-1-1. Eurocode 3: Design of steel structures--Part 1-1: General rules and rules for buildings. European Committee for Standardization, Brussels (1992)
Niemi, E.: Stress determination for fatigue analysis of welded components. Abington Publishing, Abington Cambridge (1995) Crossref
Fricke, W.: Recommended hot spot analysis procedure for structural details of ships and FPSOs based on round-robin fe analyses. Int. J. of Offshore and Polar Engng. (1), 40-47 (2002)
Dong, P.: A structural stress definition and numerical implementation for fatigue analysis of welded joints. Intl. J. Fatigue , 865876 (2001) Crossref
Partanen, T., Niemi, E.: Hot spot S - N curves based on fatigue tests of small MIG-welded aluminium specimens. IIS/IIW-1343-96 (ex. doc. XIII-1636-96/XV-921-96), Welding in the World. (1), 16-23 (1999)
Partanen, T., Niemi, E.: Collection of hot-spot S - N curves based on tests of small arc-welded steel specimens, IIW Doc XIII-1602-99, (1999)
Maddox, S.J.: Hot-spot stress design curves for fatigue assessment of welded structures. Intl. J. Offshore Polar Eng. (2), 134141 (2002)
Maddox, S.J.: Hot-spot fatigue data for welded steel and aluminium as a basis for design, IIW Document No. XIII-1900a-01, (2001)
Zhao, X.-L., Packer, J.A.: Fatigue design procedure for welded hollow section joints, Recommendations of IIW Sub-commission XV-E. Woodhead Publishing, Cambridge (2000) Crossref
G.L.: Rules for classification and construction, Part I, Ship technology, 1.1 Seagoing shipsHull, Part V, Analysis techniques, edn 1998. Germanischer Lloyd, Hamburg (1998)
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